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1. Remove seat, exposing factory computer (ECU). disconnect factory wiring by pressing lock and pushing lever back. 2. Remove ECU by pushing tab and sliding the ECU to the right as you lift. 3. Gently align the pins of the Fuelpak connector with the ECU and press the connector on the ECU. Be sure the single large pin is aligned with the single large socket before pressing Fuelpak connector into the ECU. Make sure all four tabs fully latch. (Fuelpak connector Patent Pending# 29 295831) 4. Connect factory wiring to Fuelpak connector and pull lever to locked location. Be sure that lock snaps into position. 5. Reinstall ECU. 6. Remove left side cover. 7. Slide Fuelpak down through opening leading to the area under the left side cover. 8. Attach Fuelpak to the fuse cover using supplied velcro.
HOW IT WORKS ENTERING VALUES 1. Remove Fuelpak clear case cover by removing all four screws, save hardware . 2. Turn on main power and handlebar switches, but do not start engine. Fuelpak display should light up, if not, turn power off and verify the connectors are fully seated. 3. Refer to Fuelpak Setting Reference to locate the Setting Values specific to your bike and exhaust system. If you do not find your setting, visit fuelpakfi.com or call tech support at (562) 921-0071. 4. Starting with mode 1 selected, press the value (+) or the value (-) buttons to input the correct value as indicated in your Setting Value. After entering your first value, press the mode select button to move to mode 2 and enter the value. Continue until you have entered the value for each of the first 18 mode positions. Each time the value (+) is pressed, the value increases by one number. Each time the value (-) is pressed, the value decreases by one number. (Please refer to the “How It Works” section directly above if you have questions about this step. 5. By pressing the mode select button 3-times, move to mode 21 and verify that it reads “0″ 6. Enter any other mode values as required for your application. 7. Turn power off, wait one second then turn power back on. Verify all modes then turn power off. 8. Reinstall Fuelpak clear cover then reinstall side cover

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SERIAL NUMBER LOCATIONS » OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor. Enter this number in the field on page no 1. Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hand brake lever The hand brake lever [2] is mounted on the handle bars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see maintenance work on chassis and engine). 1 A 2 B
ENGLISH 7 OPERATION INSTRUMENTS » Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks. Fuel tap The fuel tap [3] is located on the left side of the tank. Opening the fuel tap: Turn the knob all the way to the left. Closing the fuel tap: Turn the knob all the way to the right. Choke The choke button [4] is located on the left side of the carburetor. Pulling the choke button all the way out opens a bore in the carburetor through which the engine can take in additional fuel, thus achieving the „rich” fuel air mixture needed for cold starting. Pushing the choke button back in closes the bore in the carburetor. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear

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See Figure 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 5. Refer to the service manual, and follow the instructions to loosen the brake hand lever/master cylinder assembly and remove the right-side upper and lower switch housing sub-assemblies from the handlebar. It is not necessary to remove the throttle control grip. For FLHR models: Refer to the service manual. Disconnect the left-side handlebar MOLEX socket housing from the gray eight-way main harness pin housing [24B] inside the headlamp nacelle. Refer to the service manual to remove the clutch hand lever and left-side upper and lower switch housing subassemblies from the handlebar. 6. For ALL models: See Figure 2. The friction shoe (1) is a loose fit on the end of the tension adjuster screw (2). Make sure the shoe has been removed with the switch housing sub-assemblies, and is not lodged in the groove of the throttle control grip (4). 3 4 1 2 is06318 1. Friction shoe 2. Tension adjuster screw 3. Right-side lower switch housing 4. Throttle control grip Figure 2. Throttle Tension Adjuster Screw and Friction Shoe 7. See Figure 1. Verify that the 5/32-inch (4 mm) thick insert is in place between the brake lever and the lever bracket. Obtain the new right-side handlebar switch housing assembly (Item 4 or 5, depending on model) from the kit. Separate the upper and lower halves of the housing assembly. Refer to the service manual, and follow the instructions to install the switch housing assembly and brake hand lever/master cylinder assembly to the handlebar. 8. Route the right-side switch harness along the same path as the original harness (along the right handlebar). Connect the pin housing to the black socket housing disconnected in Step 3. 9. For FLHT, FLHTC, FLHX, FLHXXX and FLTRX models: Continue at Step 11. For FLHR models: Obtain the new left-side switch housing assembly (6) from the kit. Separate the upper and lower halves of the switch housing assembly. Refer to the service manual, and follow the instructions to install the left-side switch housing assembly and clutch hand lever assembly to the handlebar. 10. Route the left-side hand control harness along the same path as the original harness (along the left handlebar). Connect the pin housing to the gray socket housing disconnected in Step 5

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A. Open or remove the seat according to the service-manual instructions. !!! Warning !!! Warning To protect against shock and accidental start-up of the vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. !!! Warning !!! Warning Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. B. Disconnect the battery, negative cable first, according to the service-manual instructions. There are two options for installing the Heat Demons. Option A is doing the installation without removing the handlebar and Option B includes the removal of the handlebar. Two holes need to be drilled in the handlebar and the Option chosen depends on how comfortable the installer is on drilling holes in the bar. One advantage for removing the handlebar is the Right Handlebar Control can be left intact during the installation. The disadvantage is on some models the headlight and trim pieces need to also be removed along with the cables that are attached to the handlebar. Option A – Installation without removing the handlebar. The 4 level Controller can be mounted on the left or right side of the handlebar so choose the side and location that will provide the easiest installation and most convenient operation. The width between the holes will allow the Controller to be mounted directly to the clutch bracket or brake reservoir on many Yamaha, Honda, Kawasaki, Suzuki or Triumph motorcycles. On other motorcycles the back side clamp and cap screws are provided to mount the Controller to the handlebar

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Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hot start lever If you pull the red hot start lever [2] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a “lean” fuel-air mixture of the type needed for hot starts. 2 1 A Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. OPERATION INSTRUMENTS »
Starter button (450 SX-F) Pushing the black starter button [3] will actuate the E-starter. ENGLISH 6 Hand brake lever The hand brake lever [1] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [A] can be used to change the basic position of the hand brake lever (see “Maintenance”). Short circuit button The short circuit button [2] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open the filler cap: Turn the filler cap 45 ° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. OFF ON 1 A 2 3 ENGLISH 7 OPERATION INSTRUMENTS » Choke If you pull the choke button [1] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The result is a “fat” fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral is located between first and second gear. Kickstarter (250 SX-F) The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work). Plug in stand The plug-in stand can be attached to the wheel spindle on the left side of the motorcycle

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Clutch lever 500133-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. Hand brake lever 400196-10 Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. EmergencyOFFswitch 500144-10 The emergency OFF switch  is fitted on the left side of the handlebar. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Ignition switch 300396-10 The ignition switch  is on the right behind the headlight mask. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Electrics tarter button 500144-12 Electric starter button  is fitted on the right side of the handlebar. Possible states •Electric starter button is in home position •Electric starter button is pressed-In this position, the electric starter is actu

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To give your child a feel for the brake, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure. At the start, let your child ride to another person who can help him or her stop and turn. -Erect obstacles for your child to navigate around to accustom your child to handling the vehicle. -Yourchildshould also try to ride as slowly as possible and in a standing position to geta better feeling for the vehicle. -Donotletyour child try any off-road rides that would exceed the ability and experience of your child. -Yourchildshould hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding. -Donotexceedthe maximum allowable rider weight. Guideline Maximum rider weight <35 kg (<77 lb.) Maximum rider size Checkthegearoil level. (p. 57) (50 SXMini) -Checktheoillevel. (p. 55) -Checkthechain tension. (p. 34) -Checkthechain dirt accumulation. (p. 33) -Checkthetire condition. (p. 47) -Checkthetireair pressure. (p. 47) -Checkthefront brake fluid level. (p. 37) -Checktherear brake fluid level. (p. 42) -Checkthefront brake linings. (p. 39) -Checktherear brake linings. (p. 43) -Checkthefunction of the brake system. -Checkthecoolant level. (p. 49) -Checkthesettings of all controls and ensure that they can be operated smoothly. -Checkthe functioning of the electrical equipment. Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. -When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. -Always warmup the engine at low engine speeds. Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after along time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately.

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Please read and understand these instructions completely before installation to avoid injury or damage to the motorcycle or accessory. IMPORTANT: Dealer installation is recommended. The installer should have the service manual for the motorcycle , as well as a good understanding of motorcycle service and repair techniques. Dealer: These instructions contain important information for future reference and must be given to the customer. 1. Parts List: Item Part Name Part Number Description Qty 1 Throttle Cable Set 07-1083 1 2. Preparation: a) Before installation, lubricate cable with an appropriate cable lube such as Motion Pro Cable Lubricant (P/N 15-0002) b) Securely place motorcycle on side stand 3. Installation: Refer to vehicle service manual for installation instruction and adjustment procedures. NOTE: Notice how original cable routed before removing it. Install the accessory cable in the same way. If unsure or original cable routing, refer to the cable routing diagram in the service manual. WARNING ∞ Before starting the engine, be sure the throttle operates smoothly and check that throttle body is fully closed when throttle is released ∞ After starting the engine, turn the handlebar to the right and to the left to be sure the throttle operation is not affected ∞ Improper installation could result in great bodily injury or death 4. Maintenance: Check throttle operation before each ride. Follow Periodic Maintenance procedures in the owner’s manual for adjustment and lubrication. 5. Care and Cleaning: See your Owner’s Manual

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Control Switch Installation: Install the high/low/off switch on the left handlebar next to the grip. Do not tighten the screws too tight as the threads in the body of the switch can be stripped out. Zip-tie the switch wiring down along the bottom of the handlebar and over the front of the top triple-clamp. Wiring Harness Installation: Attach the plastic connector from the switch to its corresponding mate from the provided wiring harness. Route the harness back along the left side of the bike following the stock wiring harness to the area on top of the airbox. Make sure the key is in the off position before making these wiring connections. -Run the black wire with the ring terminal and the fused lead with the ring terminal down to the battery.

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Remove the right and left side covers. Disconnect the battery negative cable from the battery negative terminal.
2) Remove the left fairing pocket Remove the Auto volume control unit. -1 Remove the CB blind cover from the fairing by removing the four 5 x 22 mm socket head bolts. (Fig. 2) Disconnect the three wire connectors of the auto volume unit. (Fig. 3) -2 Remove the two 4 x 12mm tapping screws and remove the knob and nut from the auto volume control unit. (Fig. 1) -3 Remove the bracket form the auto volume control unit. NOTE: Discard the CB blind cover, 4 x 22mm tapping screws, and bracket. 4) Remove the seat. 5) Remove the shelter NOTE: To remove the front of the shelter, it is necessary to remove the inner cover by lifting the rear of the cover. 6) Remove the two tapping screws attaching the left coupler cover and move the holder towards the center. 7) Remove the main amplifier. -1 Disconnect the main amplifier 2-P black connector. -2 Straighten the four wire clamps at the main amplifier to release the harnesses. -3 Remove the two nuts and washers holding the main amplifier; pull the amplifier out between the left fairing pocket and handlebar by pulling up on the bottom. 8) Connect the two DIN connectors if the transceiver harness (65) to the terminal component (62) color-to-color (Fig. 7). 9) Remove the seals from the terminal component mounts inside the fairing. Position the terminal component (62) on the mounts and install using cap nuts (69) and washers (72). NOTE: Use care when installing the terminal component (62) not to push in the audio harness, CB harness and terminal component harness into the fairing pocket